Highly absorbant foamed lining

ABSTRACT

Provided in one embodiment is a cured absorbent composite comprising: liquid resistant layer of elastomer; and a layer affixed to the liquid resistant layer comprising an open foam of elastomer, wherein the moisture absorption capacity of the foam layer, normalized by the thickness of the absorptive layer, is 1.5 times that of Ansell&#39;s foam lined Household glove.

This application claims the priority of U.S. Ser. No. 61/641,696, filedMay 2, 2012, the content of which is incorporated herein in itsentirety.

Embodiments of the present invention generally relate to latex gloves,and other polymeric surfaces bondable with foam latex for which highmoisture absorbance would be useful. More specifically, embodiments ofthe invention relate to moisture absorptive gloves.

Users of latex glove are often discomforted by the buildup of sweat inthe gloves. This can lead to repeated, otherwise unnecessary, discardsof gloves. It is known to address this issue with liners made of foamlatex. U.S. Pat. No. 7,048,884 (Woodford et al.) presents an advance inmoisture absorbency whereby a highly porous open-cell foam is made.Provided herein is a method that applies a foam latex formulated to forma foam with substantial closed-cell structure, but further mechanicallyinduces an open cell structure of good absorbency. Also provided is theglove with such good absorbency.

This application relates for example to making a glove (e.g.,industrial) from synthetic lattices that are dipped into or otherwisecoated with a highly absorbent foam compound (the glove, for example,built onto a hand-shape mandrel). The foam will then be subjected toflocking or blowing fiber (e.g., natural cotton) through air onto thefoam compound to create a unique open-celled structure. In anotherembodiment, a reversed dipping or coating process uses a rough texturedformer or bisque former that is coated with a foam latex compound beforeapplying the main, liquid resistant layer to create a similar uniqueopen-celled structure.

SUMMARY OF THE INVENTION

Embodiments of the present invention generally relate to a curedabsorbent composite comprising: liquid resistant layer of polymer; and alayer affixed to the liquid resistant layer comprising an open foam ofelastomer, wherein the moisture absorption capacity of the foam layer,normalized by the thickness of the absorptive layer, is 1.5 times ormore that of Ansell's foam lined Household glove (as sold in April,2012). The composite can be formed in the shape of a glove, generallywith the foamed layer adapted to be adjacent to the user's hand.

Another embodiment relates to a method of forming a highly absorbentcomposite comprising: forming a layer of foamed elastomer; mechanicallyconverting the layer of foam elastomer from a foam structure includingclosed cell structure to a substantially more open cell structure;forming a layer of unfoamed polymer either prior to or after forming thefoamed layer, wherein the unfoamed and foamed layers are integrallyaffixed to one another; and curing the foamed layer. In embodiments,mechanically converting the layer of foam is effected by forming thefoamed layer by dipping a former with a rough surface into foamedelastomer, the rough surface effective to so convert the foamed layer.In embodiments, mechanically converting the layer of foam is effected byapplying a fibrous flock to the layer. In embodiments, mechanicallyconverting the layer of foam is effected by applying to the foam layermicronized waxes, fillers, cationic starch powders, salt particles,solidified acid particles, atomized coagulant salts or acids, or thelike.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 shows gloves made according to the invention. One glove has thecuff turned inside out to show the lining according to the invention.

FIG. 2 shows an SEM image of a lining according to the invention, formedwith the exterior process, from a perspective angle showing a cut edgeof a composite.

FIG. 3 shows the absorbency of a lining of the invention (wherein thefoam is opened with flock), as compared to other high absorbency liners.

FIG. 4 shows a cross-section that utilizes an intermediate layer.

FIG. 5 shows an exemplary mechanical conversion process wherein theconversion is applied to a top layer of foam.

FIG. 6 shows an exemplary mechanical conversion process wherein theconversion is applied to an interior or bottom layer of foam.

FIG. 7 shows an illustrative bisque texture of a former (top view, SEMphotograph).

FIG. 8 shows the open pores (SEM photograph, top view) formed on thesurface of the composite formed with a rough-surfaced former.

FIG. 9 shows an SEM cross section of a composite formed with arough-surfaced former.

FIG. 10 shows the open pores (SEM photograph, top view) formed on thesurface of the composite formed with the exterior process.

While the invention is described herein by way of example using severalembodiments and illustrative drawings, those skilled in the art willrecognize that the invention is not limited to the embodiments ofdrawing or drawings described. It should be understood that the drawingsand detailed description thereto are not intended to limit the inventionto the particular form disclosed, but on the contrary, the invention isto cover all modification, equivalents and alternatives falling withinthe spirit and scope of the present invention as defined by the appendedclaims. The headings used herein are for organizational purposes onlyand are not meant to be used to limit the scope of the description orthe claims. As used throughout this application, the word “may” is usedin a permissive sense (i.e., meaning having the potential to), ratherthan the mandatory sense (i.e., meaning must). Similarly, the words“include,” “including,” and “includes” mean including, but not limitedto. The word “glove” means glove or glove liner.

DETAILED DESCRIPTION

Embodiments of the present invention comprise a polymeric (e.g., latex)glove with a highly absorbent liner layer.

In embodiments, the moisture absorption capacity of the foam layer,normalized by the thickness of the absorptive layer, is 1.5 times ormore that of Ansell's foam lined Household glove (as sold in the U.S. inApril, 2012). In embodiments, it is 2.0 times or more, or 2.5 times ormore, or 3.0 times or more, or 3.5 times or more.

In embodiments utilizing NBR as the moisture resistant layer, themoisture absorption capacity of the foam layer, normalized by thethickness of the absorptive layer, is 5 times or more that of Ansell'sSolvex Flocklined glove (as sold in the U.S. in April, 2012). Inembodiments, it is 6 times or more, or 7 times or more, or 8 times ormore, or 9 times or more, or 10 times or more.

In embodiments, the moisture absorption capacity of the foam layer,normalized to a thickness of 0.13 mm for the absorptive layer (measuredby the foam latex, not any flock), is about 0.3 g/dm² or more, or about0.4 g/dm² or more, or 0.5 g/dm² or more. In embodiments, normalized to athickness of 0.19 mm for the absorptive layer, the moisture absorptioncapacity of the foam layer is about 0.7 g/dm² or more. In embodiments,normalized to a thickness of 0.25 mm for the absorptive layer themoisture absorption capacity of the foam layer is about 0.9 g/dm² ormore. In embodiments, normalized to a thickness of 0.275 mm for theabsorptive layer, the moisture absorption capacity of the foam layer isabout 0.6 g/dm² or more, or about 0.8 g/dm² or more, or 1.0 g/dm² ormore, or about 1.1 g/dm² or more, or about 1.2 g/dm² or more, and soforth. In embodiments, normalized to a thickness of about 0.350 mm forthe absorptive layer, the moisture absorption capacity of the foam layeris about 1.5 g/dm² or more, or about 1.6 g/dm² or more, or about 1.7g/dm² or more and so forth. In embodiments, the thickness is betweenabout 0.275 to about 0.350 mm for an absorptive capacity of betweenabout 1.0 to about 1.5 g/dm². In embodiments, normalized to a thicknessof 0.275 mm for the absorptive layer, the moisture absorption capacityof the foam layer is about 1.3 g/dm² or less.

By “mechanically converting the layer of foam elastomer from a foamstructure including closed cell structure to a substantially more opencell structure” it is meant that the foam, on curing, is substantiallymore absorbent than would apply in the absence of the mechanicalconversion. In embodiments, the foamed elastomer used to form the foamedlayer is adapted to, on curing, form a sufficiently closed cellstructure that moisture absorbency is about 50% or more lower than itwould be with the mechanical conversion. In embodiments, the foamedelastomer used to form the foamed layer is adapted to, on curing, form asufficiently closed cell structure that moisture absorbency is about 50%or more lower than it would be with the mechanical conversion using aroughened former. Or, moisture absorbency is about 60% or more lowerthan it would be with the mechanical conversion using flock. Theseimprovements compared to a lack of mechanical conversion indicatesubstantial closed cell structure prior to mechanical conversion.

The elastomeric layers may be natural rubber latex (including Guayulelatex), synthetic rubber latex, or the like, and combinations thereof.The synthetic rubber latex may be selected, for example, from the groupcomprised of polychloroprene, acrylonitrile butadiene copolymer (NBR)(such as carboxylated acrylonitrile butadiene copolymer), polyisoprene,polyurethane, styrene-butadiene, butyl, and combinations thereof.

In embodiments, the elastomer for the moisture resistant or foamed layeris predominantly NBR (50% or more). In embodiments it is substantially(90% or more by weight) NBR.

In embodiments, one or more of the polymer layers that are a moistureresistant layer have density consistent with aqueous latex dipping (asopposed for example to a density consistent with injection molding). Inembodiments, the moisture-resistant layers have other properties (suchas elasticity) consistent with aqueous latex dipping. These densities orother properties can vary with the polymer content of the elastomericlayers.

In one embodiment, the elastomeric layer(s) may have commonly usedstabilizers such as potassium hydroxide, ammonia, sulfonates and thelike. In one embodiment, the elastomeric layer(s) may contain othercommonly used ingredients such as surfactants, anti-microbial agents,fillers/additives and the like. In one embodiment, the elastomericpolymer composition used to form the moisture resistant layer has aviscosity in the range of 2000-3000 centipoises.

The foam compound formulation can comprise elastomer, curative agent andfoaming agent, and optionally one or more of thickening agent (e.g.,MHPC), flow modifier, pigment(s), and the like. Wax or filler additivesmay be added. Foaming process carried out mechanically by whipping thecompounded compound until desired foam properties such as density andviscosity are obtained. In embodiments, thickener is used to bring theviscosity of the formulation (upon foaming) to 250 cps (60 rpm) orhigher, or 300 cps or higher, or 350 cps or higher, or 400 cps orhigher. In embodiments, viscosity is kept under 700 cps, or 600 cps, 500cps, or under 450 cps. In one embodiment a latex formulation for formingthe foamed absorptive layer contains latex (e.g., NBR), potassiumhydroxide salt, flow modifier, foaming agent (sodium dodecylbenzenesulfonate), curative agent, pigment, cellulosic thickener and water.

For NBR formulations, acrylonitrile content can in embodiments be forexample about 28-42%, about 28-34%, or about 35-37%, or about 38-42% (bywt). For the interior process, about 38-42% is for example a usefulcontent. For the exterior processes, about 28-37% or about 28-34%acrylonitrile content is for example useful.

In embodiments, the elastomeric for the foamed layer is foamed usingwell-dispersed air cells, forming a structure including closed cells.Once the elastomeric coating is foamed with the right air content andthe viscosity is adjusted, refinement of the foam is undertaken forexample by using the right whipping impeller stirrer driven at anoptimal speed first and the air bubble size is refined for example usinga different impeller run at a reduced speed. Foaming process can becarried out mechanically by whipping the compounded formulation/compounduntil the desired foam properties such as density and viscosity areobtained.

In certain embodiments, foam density is about 30% or higher, or about35% or higher, or about 40% or higher. In embodiments, foam density isabout 80% or lower, or about 70% or lower, or about 60% or lower, about55% or lower, or about 50% or lower, or about 45% or lower. For theinterior process, one useful range is about 50-60% density with aviscosity of about 450-500 cps. For the exterior process, one usefulrange is about 40-45% density with a viscosity of about 400-450 cps.

In embodiments, the foam is applied by spraying. In embodiments, thefoam is applied by dipping.

In embodiments, coagulant solution (e.g., 2-10 wt % calcium nitrateaqueous solution) is applied to the former or a elastomer layer anddried prior to application of an elastomeric layer or a subsequentelastomer layer. In embodiments, the former is not treated withcoagulant prior to dipping a rough-surfaced former into foamedelastomer. In embodiments, the liquid resistant layer of elastomer isnot treated with coagulant prior to dipping into foamed elastomer. Inembodiments, the liquid resistant layer of elastomer is leached withwater (such as, for example, 40° C. water) prior to dipping into foamedelastomer.

When applying a liquid resistant layer or a foamed layer to a former, agellied coagulant can be used to act as an adhesive for the latex toadhere to the former. It contains for example calcium nitrate, wettingagent (alcohol ethoxylate and/or alkylarylalkoxylate), cellulosicthickener, water-based defoamer and water. The formulation can bedesigned to have few wetting agents in order to have optimum formerwetness to minimize potential of major defects such as holes and thinspots. The defoamer functions as a bubble inhibitor.

The liquid resistant layer can be a thick film, such as between about10-20 mil (single-walled thickness) that provides protection againstliquid permeability. It can be made for example of latex (e.g., NBR),potassium hydroxide salt, flow modifier (e.g., styrene-mono secondarybutyl maleate-monomethyl maleate-maleic anhydride polymer), curativeagents, germicide, pigments and water. A liquid resistant layer can beformed of one, two or more latex dipping steps.

After forming the liquid resistant layer or a foamed layer, a primercoagulant can be applied prior to applying an exterior layer. The primercoagulant's function is similar to gellied coagulant but optional. Abasic formulation could contain calcium nitrate, wetting agent (e.g.,alkyl trimethylammonium bromide) and water.

The flocking process can be carried out conventionally by utilizingflock booth to blow and suspend the fiber in the air, and allowing it togradually fall and adhere onto a foam-dipped former. Flock can be cottonfiber or other fiber such as rayon, bamboo or the like.

In embodiments, flock is for example 0.01 (or 0.02) to 0.3 (or 0.1, or0.2) mm in length. In embodiments, the thickness of the foamed layer isfor example 0.01 (or 0.02) to 0.3 (or 0.1, or 0.2) mm.

In the process utilizing a former with a rough surface, the un-foamed(i.e., solid) elastomer of the outer polymer layer, or the foamed orunfoamed elastomer a second (or further) outer layer can be given atexture to assist in gripping. For example, the process described inU.S. Pat. No. 7,771,644 can be used (which patent is incorporated byreference herein in its entirety). The process can be achieved bydipping straight the rough (e.g., bisque unglazed former, AlphaTECAPTformer) into a foamed nitrile compound, which creates (nearinstantaneously) an open-celled structure on the contacting surfaces ofthe former.

The rough surface can be created by applying an adhesive (e.g.,water-soluble polymer adhesive, such as without limitationpolyvinylidine prollidione (PVP)) in or in conjunction with a coagulantprimer onto a smooth former surface and then spraying on particles, suchas salt, PE, PP, and the like (which can be for example micronizedparticles).

Roughness measures for three formers useful in the interior method areas follows:

Type of Former Z51 Parameters (former from MIM) AlphaTec HWT Solvex Ra4.031 μm  7.257 μm  10.77 μm  Rz 24.6 μm 36.7 μm 47.6 μm Rmax 26.1 μm43.6 μm 69.4 μm Rp 12.9 μm 19.9 μm 25.6 μm Rv 11.7 μm 16.8 μm 22.1 μmRPc 80 60 33 Legend: 1) Roughness average, Ra- the arithmetic average ofthe absolute values of the roughness profile ordinates. 2) Meanroughness depth, Rz- the arithmetic mean value of the single roughnessdepth of consecutive sampling length. 3) Maximum roughness depth, Rmax-the largest single roughness depth within the evaluation length. 4) Peakheight, Rp- the height of the highest profile peak of the roughnessprofile within one sampling length. 5) Valley height, Rv- Depth of thedeepest profile valley within one sample length. 6) Peak count, Rpc-Number of roughness profile elements per cm, which consecutivelyintersect the specified upper profile section C1 and lower profilesection C2 (See ISO 4287 and Perthometer, Surface Texture Parameters:New Standards KIN EN ISO/ASME, MAHR GMBH, Germany, 1999, the contentsrelevant to ISO 4287 measurements incorporated by reference).

The roughness of the formers was measured using test method available inS&T quality system (TM.028 Determination of Coating Thickness andSurface Roughness Properties (Rev0), methodology based on ISO 4287).Thus, in embodiments, the interior method uses a former with a Ra ofabout 3 micron or more, such as about 4 micron or more, and so forth,including about 9 micron or more. In embodiments, the Ra is 11 micron orless. In embodiments, the interior method uses a former with a Rz ofabout 20 micron or more, about 25 micron or more, and so forth includingabout 40 or about 45 micron or more. In embodiments, the Rz is about 47micron or less. In embodiments, the interior method uses a former with aRPc of about 20 or more. In embodiments, the interior method uses aformer with a RPc of about 120 or less. In embodiments, any combinationof two or more of the recited parameter boundaries for Ra, Rz or RPcapplies.

The process as outlined focuses on a foamed layer and a moistureresistant layer to which it is adhered. It will be recognized that therecan be additional layers, such as additional moisture resistant layer(s)or a layer utilized to provide an external textured surface. Moreover,the foamed and moisture resistant layers may be adhered via anintermediate elastomer layer, such as illustrated in FIG. 4. Theintermediate elastomer layer can include a contamination indicator, suchas taught in PCT/US11/48589 (which application is incorporated herein byreference in its entirety).

As can be seen in FIGS. 2 and 10, the flock fibers are effective topenetrate the foam layer, and thereby further open the cells of the foamlayer.

FIG. 3 compares moisture absorption capacity of glove of the invention,and Ansell Virtex™, Ansell Solvex™ Flocklined and Ansell Foam LinedHousehold gloves.

The elastomeric coating is breathable preventing the glove from becomingclammy. In one embodiment, an aqueous fluorochemical dispersion coatingmay be applied to the glove to further prevent liquid from penetration.The aqueous fluorochemical dispersion comprises an aqueous solventmedium to form a coating that is typically 0.5 to 2 micron in thickness.The aqueous fluorochemical dispersion may also be applied to a glovewith unfoamed elastomeric coating to prevent oil or water penetrationthrough occasional imperfections in the elastomeric coating. Methods forincorporating high air contents into elastomer foams are described inWoodford et al., U.S. Pat. No. 7,048,884, which is incorporated hereinin its entirety.

A. Exterior Process

An exemplary process applying mechanical conversion from the exterior isshown in FIG. 5. The non-optional steps are foam dipping, flocking andcuring. FIG. 4 shows an illustrative cross-section, with flock 10, foamlayer 20, optional chemical indicator layer 30, and shell layer 40.

A1. Dipping Process

In one embodiment, the liquid resistant layer is formed by a dippingprocess. The process can start with former cleaning using acid solutionto ensure the surface is clean from any foreign particle. A rinsingprocess is typically carried out prior to coagulant dipping (e.g.,gellied). Concentration and temperature of coagulant is controlled toensure formation of uniform coating. Timing of former immersion,dwelling and extraction can also be controlled to minimize bubblecreation. Former can be dried at ambient or heated temperature,typically with former position pointing upward to ensure free flow ofcoagulant and optimum film dryness prior to latex dipping. Once theformer is sufficiently dried, latex dipping is started. Similar to thecoagulant dipping, a number of factors are controlled withinspecification. Leaching process to remove excess chemical typicallyresidual takes place after latex dip. Leach water temperature and timingis selected to ensure optimum leaching process. After leaching, formerwill typically undergo primer coagulant dipping before again being driedin anticipation of foam dipping. Foam properties such as the viscosityand density are locked within specification in order to get requiredfilm thickness and absorption. The foam is subjected to the flockingprocess. Finally, the glove can be pre-cured at ambient temperature forapproximately 5 minutes before curing process started at 90-130° C. for1-2 hours. The absorbent composite will typically undergo cooling,online chlorination and rinsing before the stripping process.

A2. Foaming Process

The foaming process is typically carried out mechanically by whippingthe compounded compound until desired foam properties (foam density andviscosity) are achieved. On a laboratory scale, a high-speed stirrer canbe used and the speed is typically set between 800-1600 rpm depending ontargeted properties. For large scale, a foaming machine can be utilizedand foam properties are set by adjusting the pump speed and mixer speed.

A3. Flocking Process

The flocking process can be carried out conventionally by utilizingflock booth to blow and suspend the cotton fiber in the air before itgradually falls and adheres onto the foam layer. This process willcreate an open-celled foam structure that able to absorb significantamount of moisture. It also helps to absorb moisture faster and providecomfort to the wearer. Electrostatic flocking processes can be used.

B. Interior Process

FIG. 6 shows an exemplary mechanical conversion process wherein theconversion is applied to an interior or bottom layer of foam. Theinitial coagulant application, foam dipping and shell dipping steps arethe non-optional steps.

In embodiments, the rough former is contacted with flock after coagulantdipping. In embodiments, the foam is applied by spraying. In embodimentsusing flock, the former is treated with a water soluble polymer binderand release agent such as Luviquat PQ11 or release agent such as PEG 400prior to flocking. In embodiments, the former is treated with onerelease agent (e.g., Luviquat PQ11) prior to flocking, and another(e.g., PEG 400) after flocking but prior to application of the foam.

In embodiments, the former is treated with one water-soluble binder(Luviquat PQ 11) in a coagulant solution prior to fluidized sprayapplication of solid non-coagulant particles such as calcium carbonateor the former is treated with one water soluble binder (Luviquat PQ 11)prior to fluidized spray application of solid water-soluble coagulantparticles such as sodium chloride, sodium sulphate etc. in the initialcoagulant formulation for the interior process. The non-coagulantparticles can be removed by acid off-line washing process and thecoagulant particles by normal off-line washing process.

In embodiments using the interior process, the former temperature is 60°C. or less, or 55° C. or less, or 50° C. or less, or 45° C. or less.

All ranges recited herein include ranges therebetween, and can beinclusive or exclusive of the endpoints. Optional included ranges arefrom integer values therebetween (or inclusive of one originalendpoint), at the order of magnitude recited or the next smaller orderof magnitude. For example, if the lower range value is 0.2, optionalincluded endpoints can be 0.3, 0.4, . . . 1.1, 1.2, and the like, aswell as 1, 2, 3 and the like; if the higher range is 8, optionalincluded endpoints can be 7, 6, and the like, as well as 7.9, 7.8, andthe like. One-sided boundaries, such as 3 or more, similarly includeconsistent boundaries (or ranges) starting at integer values at therecited order of magnitude or one lower. For example, 3 or more includes4 or more, or 3.1 or more.

EXAMPLE 1

Dipping process is conducted as per the sequence in FIG. 5. Typicalformulation of gellied coagulant, compound base 1 and primer coagulantare as shown below. Formulation of foam is shown in Table 4. Foamingprocess is carried out using high-speed stirrer. The speed and timing ofthe process has been adjusted accordingly until desired foam propertiesachieved.

TABLE 1 Formulation of gellied goagulant % TSC Materials Part (w/w) 78Calcium nitrate 30-40 20 Wetting agent #2 0.01-0.25 20 Wetting agent #20.1-0.2 1 Cellulosic thickener 0.1-0.5 1 Water-based defoamer0.001-0.005

TABLE 2 Formulation of compound base 1 % TSC Materials Phr 44 Nitrilelatex 100 5 Potassium Hydroxide 0.1-0.5 10 Flow modifier 0.1-1.0 50Curative agent  1.0-10.0 7.5 Germicide 0.1-0.5 100 Pigment  1.0-10.0

TABLE 3 Formulation of primer coagulant % TSC Materials Part (w/w) 78Calcium nitrate 15-25 100 Wetting agent 0.1-0.5

TABLE 4 Formulation of foam % TSC Materials Phr 44 Nitrile latex 100 5Potassium hydroxide 0.25 10 Flow modifier 0.20 30 Foaming agent 1.00 50Curative agent 1.50 100 Pigment 0.05 6 Cellulosic thickener 0.50

Wax at 100% TSC and 0.035 Phr is an option.

Illustrative properties of each formulation/compound are shown below:

Type of compound Gellied Primer Compound Compound Parameters coagulantcoagulant base 1 base 2 TSC % N/a N/a 38-45 38-45 pH N/a N/a 8.8-9.88.8-9.8 Viscosity, cps N/a N/a 18-22 N/a Concentration, % 30-40 15-25N/a N/a Foam viscosity, % N/a N/a N/a 350-450 Foam density, % N/a N/aN/a 40-50

EXAMPLE 2

An illustrative interior process is conducted per the process of FIG. 6(with or without chlorination, and with and without overdip), with thefollowing formulations:

TABLE 5 Initial Coagulant (with polyox) % Chemicals Dry (phr) Wet (phr)78 Calcium nitrate 7 8.97 50 Mesamoll 1 2 1 Polyox 301 0.01 1 100 Water— 88.03 Total 100 Remark: Spray the CN with Polyox on hot former surface

TABLE 6 Foam NBR A % Chemicals Dry (phr) 44 High ACN(40%) NBR 100 5 KOH0.25 11.3 Scripset 550 0.2 30 Calsoft L60 1 50 ZnO 1.5 100 DVM Grey Mod2 0.05 6 MPHC-50 0.45 Total 103.45

For the second priming, one of:

TABLE 7 27% gellied Priming TSC Chemicals Dry (phr)  78% Calcium nitrate27 100% TERIC 320 0.018 100% SURFYNOL TG 0.06 1.50%  CELLOSIZE SOL 0.11100% DEFOAMER 1512M 0.003 100% water — TOTAL 27.191

TABLE 8 47% Coagulant TSC Chemicals Dry (phr) Wet (phr)  78% Calciumnitrate 47 60.26 100% Water — 39.74 Total 47 100

TABLE 9 Formulation of Shell TSC (%) Chemicals Dry (phr) Wet (phr) 45NBR A 100.00 222.22 5 KOH 0.55 11.00 50 COMPOSITE 5.50 11.00 10 SCRIPSET550 0.50 5.00 7.50 NIPACIDE TK 0.25 3.33 50 FREESIL N 0.60 1.20 100HYDROTINT RED 187C 4.00 4.00 TOTAL 111.40 257.76

The former utilized had texture as shown in FIG. 7.

EXAMPLE 3

An illustrative interior process is conducted per the process of FIG. 6(with or without chlorination) with the formulations of Example 2, andthe following overdip formulation:

TABLE 14 Overdip formulation TSC Chemicals Dry (phr)  45% High ACN (40%)NBR 100  5% KOH 0.55  50% COMPOSITE A345 4 7.50%  NIPACIDE TK 0.25 100%DVM GREY MOD 4 100% HYDROTINIT BLACK 3115 0.5  6% ACRYSOL G-111 1.2Total 110.5

Salt application for exterior texturing was according to the method ofU.S. Pat. No. 7,771,644, which is incorporated herein for theseteachings in their entirety. Absorbencies of the interior layer of1.8-2.2 g/dm² are obtained.

Misc. Embodiments

A. A glove construction comprising dipping in a gellied coagulant, a NBRlatex, a primer coagulant, a NBR foam latex and flock fibres.

B. A glove construction reversed to that of A comprising dipping in acoagulant dip, a NBR foam latex, a primer coagulant, a NBR latex andsalt texturised thickened NBR latex.

C. A glove as recited above with foam NBR latex with open-celledstructure for high absorption moisture capabilities.

D. A glove as recited above formed through impregnation of particlessuch as flock fibres, micronized waxes, fillers, cationic starchpowders, salt particles, solidified acid particles, or atomizedcoagulant salts or acids to create an open-celled porous structure.

E. A glove as recited above formed through overdipping a roughenedtexture or bisque former into a foam NBR latex compound.

F. A glove as recited above can also be made of any other polymer latexfoam compound such as Chloroprene latex, NR latex, PU latex, PI latex,Guayule and butyl latex, and the like, or their blends.

G. A glove as recited above whereby the foam latex is whipped to around30-80% of foam density, or around 40-70%, or around 50-60%.

H. A glove as recited above that is on-line chlorinated or off-linechlorinated for ease of donning.

Embodiment 1

A cured absorbent composite comprising: liquid resistant layer ofpolymer; and a layer affixed to the liquid resistant layer comprising anopen foam of elastomer, wherein (a) the moisture absorption capacity ofthe foam layer, normalized by the thickness of the absorptive layer, is1.5 times that of Ansell's foam lined Household glove, or (b) themoisture absorption capacity of the foam layer, normalized to athickness of 0.275 mm for the absorptive layer, is about 0.6 g/dm 2 ormore.

Embodiment 2

The cured absorbent composite of embodiment 1, wherein the moistureabsorption capacity of the foam layer, normalized by the thickness ofthe absorptive layer, is 1.5 times that of Ansell's foam lined Householdglove.

Embodiment 3

The cured absorbent composite of embodiment 1 or 2, wherein the moistureabsorption capacity of the foam layer, normalized to a thickness of0.275 mm for the absorptive layer, is about 0.6 g/dm 2 or more.

Embodiment 4

The cured absorbent composite of embodiment 1 or 2, wherein the moistureabsorption capacity of the foam layer, normalized to a thickness of0.275 mm for the absorptive layer, is about 1.0 g/dm 2 or more.

Embodiment 5

The cured absorbent composite of a foregoing embodiment, formed as aglove with the open foam on the interior for absorbing user sweat.

Embodiment 6

A method of forming a highly absorbent composite comprising: forming alayer of foamed elastomer; mechanically converting the layer of foamelastomer from a foam structure including closed cell structure to asubstantially more open cell structure; forming a layer of unfoamedpolymer either prior to or after forming the foamed layer, wherein theunfoamed and foamed layers are integrally affixed to one another; andcuring the foamed layer.

Embodiment 7

The cured absorbent composite of a embodiment 1 to 5, or the method ofembodiment 6, wherein in the absence of mechanical conversion the waterabsorbancy of the foam layer would be about 50% or more lower.

Embodiment 8

The cured absorbent composite of embodiment 6 or the method ofembodiment 6 or 7, wherein the composite is formed as a glove with theopen foam on the interior for absorbing user sweat.

Embodiment 9

The cured absorbent composite of a embodiment 1 to 5, or the method ofembodiment 6, wherein mechanically converting the layer of foam iseffected by forming the foamed layer by dipping a former with a roughsurface into foamed elastomer, the rough surface effective to so convertthe foamed layer, optionally the former having a Ra of about 3 micron ormore and/or a Rz of 20 micron or more.

Embodiment 10

The cured absorbent composite of embodiment 9, or the method ofembodiment 9, wherein in the absence of mechanical conversion the waterabsorbancy of the foam layer would be about 50% or more lower.

Embodiment 11

The method of embodiment 9 or 10, wherein the composite is formed as aglove with the open foam on the interior for absorbing user sweat.

Embodiment 12

The cured absorbent composite of a embodiment 9-11 or the method of aembodiment 9-11, wherein the foamed elastomer used to form the foamedelastomer layer has about 50-60% density with a viscosity of about450-500 cps.

Embodiment 13

The cured absorbent composite of embodiment 9 or 12 or the method ofembodiment 9 or 12, wherein the foamed elastomer is NBR with aacrylonitrile content of 38 to 42% wt.

Embodiment 14

The cured absorbent composite of a embodiment 1 to 5, or the method ofembodiment 6, wherein mechanically converting the layer of foam iseffected by applying a fibrous flock to the layer.

Embodiment 15

The cured absorbent composite of embodiment 14, or the method ofembodiment 14, wherein in the absence of mechanical conversion the waterabsorbancy of the foam layer would be about 60% or more lower.

Embodiment 16

The cured absorbent composite of a embodiment 14 or 15, or the method ofembodiment 14 or 15, wherein the composite is formed as a glove with theopen foam on the interior for absorbing user sweat.

Embodiment 17

The cured absorbent composite of a embodiment 14-16 or the method of aembodiment 14-16, wherein the foamed elastomer used to form the foamedelastomer layer has about 40-45% density with a viscosity of about400-450 cps.

Embodiment 18

The cured absorbent composite of a embodiment 14-17 or the method of aembodiment 14-17, wherein the foamed elastomer is NBR with aacrylonitrile content of 28 to 34% wt.

Embodiment 19

The cured absorbent composite of a embodiment 1 to 5, or the method ofembodiment 6, wherein mechanically converting the layer of foam iseffected by applying to the foamed layer micronized waxes, fillers,cationic starch powders, salt particles, solidified acid particles, oratomized coagulant salts or acids.

Embodiment 20

The cured absorbent composite of embodiment 19, or the method ofembodiment 19, wherein in the absence of mechanical conversion the waterabsorbancy of the foam layer would be about 50% or more lower.

Embodiment 21

The cured absorbent composite of a embodiment 19 or 20, or the method ofembodiment 19 or 20, wherein the composite is formed as a glove with theopen foam on the interior for absorbing user sweat.

The foregoing description of embodiments of the invention comprises anumber of elements, devices, machines, components and/or assemblies thatperform various functions as described. These elements, devices,machines, components and/or assemblies are exemplary implementations ofmeans for performing their respectively described functions.

Although only a few exemplary embodiments of the present invention havebeen described in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention.

The invention claimed is:
 1. A method of forming a highly absorbentcomposite glove comprising: dip forming a layer of foamed elastomer on aformer with a rough surface, wherein the former has a Ra of about 3micron or more, thereby mechanically converting the layer of foamelastomer from a foam structure including closed cell structure to asubstantially more open cell structure; forming a layer of unfoamedpolymer, wherein the unfoamed and foamed layers are integrally affixedto one another; curing the foamed layer to form the glove, wherein inthe absence of mechanical conversion the water absorbancy of the foamlayer would be about 60% or lower than occurs with mechanicalconversion; and configuring the gloves for use by the consumer with theopen foam on the interior for absorbing user sweat, wherein sweatabsorption is due to the foamed, cured elastomer.
 2. The method of claim1, wherein the moisture absorption capacity of the cured foamed layer,normalized to a thickness of 0.275 mm for the absorptive layer, is about0.6 g/dm² or more.
 3. The method of claim 2, wherein the former has a Rzof 20 micron or more.
 4. The method of claim 2, wherein the foamedelastomer used to form the foamed elastomer layer has about 50-60%density with a viscosity of about 450-500 cps.
 5. The method of claim 4,wherein the foamed elastomer is NBR with a acrylonitrile content of 38to 42% wt.
 6. The method of claim 1, wherein forming the layer of foamedelastomer comprises dipping a former, with or without elastomercoatings, into foamed elastomer.
 7. The method of claim 6, wherein thefoamed elastomer used to form the foamed elastomer layer has a foamdensity ranging from 30-60% and a viscosity ranging from 300 to 500 cps.